Method and apparatus for controlling anode pH in membrane chlor-alkali cells

Claim 2

In a process wherein an aqueous alkali metal chloride solution is electrolyzed in a chlor-alkali appartus including a cell having an anode compartment containing an anode capable of generating chlorine and lesser amounts of oxygen from aqueous chloride solution, a cathode compartment containing a cathode and a substantially fluid impervious, cation permselective membrane separting said anode compartment from said cathode compartment, the improvement comprising controlling the pH of the anolyte by operating said anode to have an oxygen evolution efficiency substantially chemically equivalent to the hydroxide ion transfer efficiency of the said membrane whereby the formation of excessive chlorates and hypochlorites in said anolyte and insoluble metallic hydroxide in said membrane is substantially reduced.

Claim 3

A chlor-alkali apparatus including a cell comprising an anode compartment containing an anode, a cathode compartment containing a cathode, a substantially fluid impervious cation permselective membrane separating said anode and cathode compartments, said membrane having a hydroxide ion transfer efficiency, said anode having an oxygen evolution efficiency substantially equivalent chemically to said hydroxide ion transfer efficiency of said membrane.

Claim 4

A chlor-alkali apparatus including a cell comprising an anode compartment containing an anode, a cathode compartment containing a cathode, a substantially fluid impervious cation permselective membrane separating said anode and cathode compartments, said membrane having a hydroxide ion transfer efficiency, said anode having an oxygen evolution efficiency substantially equivalent chemically to said hydroxide ion transfer efficiency of said membrane.

Claim 5

The apparatus of claim 2 in which the anode is a composite anode having at least one region having a higher oxygen evolution efficiency than the remaining regions of said composite anode.

Claim 6

The apparatus of claim 3 including means for separately controlling the current density in said one region relative to said remaining regions of said composite anode.

Claim 7

The apparatus of claim 3, wherein said composite anode comprises at least one region containing a coating of manganese dioxide having a high efficiency for oxygen evolution.

Claim 8

Apparatus according to claim 2 in which at least one of the electrodes is foraminous and is in contact with the membrane.

Claim 9

Apparatus according to claim 6 wherein a catalytically active layer for said electrode is partially imbedded in the membrane.

Claim 10

The apparatus according to claim 2 in which the membrane comprises a perfluorocarbon having active groups selected from the group consisting of sulfonate, sulfonamide, carboxylate and phosphonate and has a hydroxide ion transfer efficiency of more than about 5 percent.

Claim 11

Apparatus according to claim 2 in which the anode is a composite anode having at least one region having an oxygen evolution efficiency of at least about 95 percent, the remaining regions having a chlorine evolution efficiency of at least about 95 percent, the ratio of the active areas of said one region to the active area of said remaining region being substantially equal to the ratio of the hydroxide ion transfer efficiency of said membrane to the cation transfer efficiency.

Claim 12

Apparatus according to claim 2 including: (a) means for measuring the pH of the liquid effluent from the anode compartments; (b) pH responsive means for increasing the fraction of said liquid effluent which is recycled to said anode compartment after substantial resaturtion when said pH increases and for decreasing the fraction when said pH decreases.

Claim 13

A chlor-alkali apparatus comprising: (a) at least one electrolytic cell comprising an anode compartment containing an anode, a cathode compartment containing a cathode, a substantially fluid impervious cation permselective membrane separating said anode and cathode compartments, said membrane having a finite hydroxide ion transfer efficiency, said anode having an oxygen evolution efficiency substantially equivalent chemically to said hydroxide ion transfer efficiency of said membrane; (b) means for controlling the temperature of the fluid immediately effluent from said cathode compartment to the range of from about 70° to about 95° C.; (c) means for controlling the concentration of the effluent from said cathode compartment to at least about 8 percent by weight of alkali hyroxide; and (d) means for controlling the current density at said membrane to the range of from about 10 to about 35 amperes per square decimeter.

Claim 14

A chlor-alkali apparatus comprising: (a) at least one electrolytic cell comprising an anode compartment containing an anode, a cathode compartment containing a cathode, a substantially fluid impervious cation permselective membrane separating said anode and cathode compartments, said membrane having a finite hydroxide ion transfer efficiency, said anode having an oxygen evolution efficiency substantially equivalent chemically to said hydroxide ion transfer efficiency of said membrane; (b) means for controlling the temperature of the fluid immediately effluent from said cathode compartment to the range of from about 70° to about 95° C.; (c) means for controlling the concentration of the effluent from said cathode compartment to at least about 8 percent by weight of alkali hyroxide; and (d) means for controlling the current density at said membrane to the range of from about 10 to about 35 amperes per square decimeter.

Claim 15

Apparatus according to claim 11 including means for controlling the concentration of any non-monovalent cation in the liquid feed to said anode compartment to less than about 2 ppm.

Claim 16

A chlor-alkali apparatus including: (a) at least one electrolytic cell comprising an anode compartment containing a coated electrolytic valve metal anode, a cathode compartment containing a cathode, a substantially fluid impervious perfluorocarbon cation permselective membrane having active groups selected from the group consisting of sulfonate, sulfonamide, carboxylate and phosphonate separating said anode and cathode compartments, said membrane having a hydroxide ion transfer efficiency in excess of about 5 percent, said anode having an oxygen evolution efficiency substantially equivalent chemically to said hydroxide ion transfer efficiency of said membrane; (b) means for separating the liquid effluent from the cathode compartment from the gaseous effluent therefrom; (c) means for cooling the liquid effluent by evaporation to a temperature of substantially less than about 70° C.; (d) means for measuring the temperature of the liquid immediately effluent from said cathode compartment; (e) temperature responsive means for controlling the temperature of said liquid immediately effluent to the range of from about 70° to about 95° C. by exchanging heat between said cooled liquid effluent and the influent to said cathode compartment.

Claim 17

A chlor-alkali apparatus including: (a) at least one electrolytic cell comprising an anode compartment containing a coated electrolytic valve metal anode, a cathode compartment containing a cathode, a substantially fluid impervious perfluorocarbon cation permselective membrane having active groups selected from the group consisting of sulfonate, sulfonamide, carboxylate and phosphonate separating said anode and cathode compartments, said membrane having a hydroxide ion transfer efficiency in excess of about 5 percent, said anode having an oxygen evolution efficiency substantially equivalent chemically to said hydroxide ion transfer efficiency of said membrane; (b) means for separating the liquid effluent from the cathode compartment from the gaseous effluent therefrom; (c) means for cooling the liquid effluent by evaporation to a temperature of substantially less than about 70° C.; (d) means for measuring the temperature of the liquid immediately effluent from said cathode compartment; (e) temperature responsive means for controlling the temperature of said liquid immediately effluent to the range of from about 70° to about 95° C. by exchanging heat between said cooled liquid effluent and the influent to said cathode compartment.

Claim 18

A chlor-alkali apparatus including: (a) an array of electrolytic cells arranged in stages with each cell comprising an anode compartment containing a coated metallic anode, a cathode compartment containing a metallic cathode, a substantially fluid impervious perfluorocarbon cation permselective membrane separating said anode and cathode compartments, said membrane having a hydroxide ion transfer efficiency of more than about 5 percent, but less than about 30 percent, said anode having a chlorine evolution efficiency of less than about 98 percent but more than about 70 percent; (b) means for passing at least part of the combined liquid effluent from the cathode compartment(s) from a first stage of such array as influent to the cathode compartment(s) of a second stage of such array; (c) means for recycling the remainder of said combined liquid effluent and adder water as influent to the cathode compartment(s) of said first stage; and (d) means for controlling the concentration of the combined liquid effluent from the cathode compartment(s) of such first stage to the range of from about 9 to about 13 percent by weight.

Claim 19

A chlor-alkali apparatus including: (a) an array of electrolytic cells arranged in stages with each cell comprising an anode compartment containing a coated metallic anode, a cathode compartment containing a metallic cathode, a substantially fluid impervious perfluorocarbon cation permselective membrane separating said anode and cathode compartments, said membrane having a hydroxide ion transfer efficiency of more than about 5 percent, but less than about 30 percent, said anode having a chlorine evolution efficiency of less than about 98 percent but more than about 70 percent; (b) means for passing at least part of the combined liquid effluent from the cathode compartment(s) from a first stage of such array as influent to the cathode compartment(s) of a second stage of such array; (c) means for recycling the remainder of said combined liquid effluent and adder water as influent to the cathode compartment(s) of said first stage; and (d) means for controlling the concentration of the combined liquid effluent from the cathode compartment(s) of such first stage to the range of from about 9 to about 13 percent by weight.

Claim 20

Apparatus according to claim 14 including: (a) means for controlling the pH of the liquid effluent from the anode compartments in the range of from about 2 to about 4; (b) means for controlling the temperature of the liquid immediately effluent from the cathode compartments to the range of from about 70° to about 95° C.; (c) means from controlling the chloride in the liquid effluents from said anode compartments to a concentration of not less than about 3 gram equivalents per liter.

Claim 21

Apparatus according to claim 14 in which the product of the average current density in the first stage by the active membrane area in that stage is substantially greater than the product of the average current density in any subsequent stage by the active membrane area of such subsequent stage.